Modeling of sponges and open- and closed-cell foams
FoamGeo
FoamGeo creates advanced digital 3D models, called digital twins, of Kelvin cells, sponges, and open- and closed-cell foams. Typical application areas are insulation materials like closed cell polyethylene foams, dampening materials, acoustics, and metal foams. Our modeling process begins with a statistical description of the material, encompassing key parameters like the solid volume percentage, the cell size distribution, the cell shape, the cell orientation, the cell wall thickness, the strut diameter, and the strut shape.
In instances where the statistical input parameters of the foam cells are unidentified, our innovative PoroDict module comes into play. With the use of 3D scans of actual materials, PoroDict effectively determines the cell parameters, thereby ensuring accuracy and reliability in the modeling process.
The resulting digital 3D microstructure model,or digital twin, of a foam offers an unparalleled level of detail, facilitating analyses that are comparable to those obtained from traditional µCT scans. The analysis capabilities include the computation of the pore-size distribution (using the PoroDict module) and the simulation of mechanical properties (using the ElastoDict module).
A digital twin based on a statistical model is an extremely powerful tool for the digital design of materials than a single CT scan. A digital twin allows the exploration of various material structures by digitally manipulating the underlying parameters. For example, for a foam, it is very easy to study the influence of a different cell size distribution on its mechanical stability.
Statistical digital twin of an aluminum foam
Match geometric properties:
- SVP: 4.74 %
- Cell-size distribution
- Cell anisotropy and orientation
- Strut shape and diameter distribution
(a) CT scan, (b) Statistical digital twin
Generation of complex foams
In combination with the GrainGeo, GadGeo,
and ProcessGeo modules, more complex shapes,
such as foam beads can be generated.
Generation of a foam with FoamGeo
User-friendly GUI to generate a random foam
- With closed- or open-cells.
- With user-defined cell size distribution.
Thanks to the voxel-based generation, there is
- No need for beam elements.
- No need for a complicated mesh.
FoamGeo includes two options to generate sponges and foams.
The Kelvin Structure option allows for the creation of regular foams and sponges, wherein the fundamental structural units are Kelvin cells. The Kelvin Structure option allows the design of foams with open, partially closed, or fully closed cell walls, depending on the desired properties. The struts forming the structure can be configured with circular, hollow, or (tri-)angular cross-sections. Additionally, the thickness of the cell walls and the diameters of the struts can be precisely adjusted to tailor the foam's structural and mechanical characteristics.
The Random Foam option, on the other hand, allows the generation of foams with irregular, randomly distributed cells. Users can define the size distribution, anisotropy, and orientation of the cells to create a custom random geometry. With regard to the Kelvin structure, the cell walls and strut shapes can be specified. Additionally, it is possible to control the solid volume fraction of the foam structure, enabling precise customization of its density and material properties.
Following Modules are often used in combination with FoamGeo:
| Image Processing and Image Analysis | ImportGeo-Vol | ||||
| Material Analysis | PoroDict + MatDict | ||||
| Modeling & Design | |||||
| Simulation & Prediction | ConductoDict | DiffuDict | ElastoDict | FlowDict | AcoustoDict |
| Interfaces | ExportGeo-CAD + MeshGeo |
Suitable modules depend on the concrete application.